Form No. 3355-998 Rev B Z595-D Z Master® with 52in or 60in TURBO FORCE® Side Discharge Mower Model No. 74266—Serial No. 270000001 and Up Model No. 74267—Serial No. 270000001 and Up Register at www.Toro.com.
Warning CALIFORNIA Proposition 65 Warning The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Important: This engine is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate the engine on any forest-covered, brush-covered, or grass-covered land. Other states or federal areas may have similar laws. Figure 1 1.
Using the Rollover Protection System (ROPS) .......................................................... 16 Think Safety First ............................................... 17 Operating the Parking Brake ............................... 17 Starting and Stopping the Engine ........................ 18 Operating the Power Take Off (PTO) ................. 19 The Safety Interlock System................................ 20 Driving Forward or Backward............................. 20 Stopping the Machine.............
Safety • Use extra care when handling diesel and other fuels. They are flammable and vapors are explosive. – Use only an approved container – Never refuel or drain the machine indoors. – Never remove gas cap or add fuel with engine running. Allow engine to cool before refueling. Do not smoke. • Check that operator’s presence controls, safety switches and shields are attached and functioning properly. Do not operate unless they are functioning properly.
• Check the area to be mowed and never fold the ROPS in areas where there are slopes, drop offs or water. • Use extreme care when loading or unloading the machine into a trailer or truck. • Use care when approaching blind corners, shrubs, trees, or other objects that may obscure vision. • Lower the rollbar only when absolutely necessary. Do not wear the seat belt with the roll bar folded down. Slope Operation • Check carefully for overhead clearances (i.e.
Slope Chart 6
Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. 66-1340 1-523552 65-2690 1-643253 68-8340 54-9220 98-4387 1. Warning—wear hearing protection. 98-5954 58-6520 1.
103-1636 105-7798 106-7492 106-9989 8
107-1613 107-1622 107-1860 107-1857 107-1861 9
7-1864 107-2449 108-5955 107-2102 108-5957 107-2112 10
0-3852 1. Remove the ignition key and read the instructions before servicing or performing maintenance. 108-5981 2. Continuous tone signals the user that engine is overheating. 110-0305 110-3853 1. Cutting/dismemberment hazard, fan and entanglement hazard, belt. 2. Remove the ignition key and read the instructions before servicing or performing maintenance. Manufacturer’s Mark 1. Indicates the blade is identified as a part from the original machine manufacturer. 110–0806 110-3851 1.
112-8319 112-2389 1. Push to engage 2. Engine—preheat 3. Read the Operator’s Manual. 4. Engine—stop 5. Engine—run 110-0819 12 6. Engine—start 7. Fast 8. Continuous variable setting 9. Slow 10.
Hour Meter Product Overview The hour meter records the number of hours the engine has operated. It operates when the engine is running. Use these times for scheduling regular maintenance (Figure 4). Glow Plug Light The glow plug indicator light turns on when the glow plug button is engaged (Figure 4). Glow Plug Switch This switch activates the glow plugs and is indicated by the glow plug light. Hold down the glow plug switch for 10 seconds prior to starting.
Operation In certain conditions, diesel fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property. Note: Determine the left and right sides of the machine from the normal operating position. Adding Fuel • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any fuel that spills. The engine runs on clean, fresh diesel fuel with a minimum cetane rating of 40.
3. Install fuel tank caps securely. Wipe up any fuel that may have spilled. In certain conditions during fueling, static electricity can be released causing a spark which can ignite the fuel vapors. A fire or explosion from fuel can burn you and others and can damage property. 4. If possible, fill the fuel tank after each use. This will minimize possible buildup of condensation inside the fuel tank.
Using the Rollover Protection System (ROPS) To avoid injury or death from rollover: keep the roll bar in the raised locked position and use the seat belt. Ensure that the rear part of the seat is secured with the seat latch. Figure 6 1. Full down position There is no rollover protection when the roll bar is in the down position. 2. Down position with bagger installed Important: Ensure that the rear part of the seat is secured with the seat latch. • Lower the roll bar only when absolutely necessary.
Think Safety First Please read all safety instructions and symbols in the safety section. Knowing this information could help you or bystanders avoid injury. Operating on wet grass or steep slopes can cause sliding and loss of control. Wheels dropping over edges can cause rollovers, which may result in serious injury, death or drowning. There is no rollover protection when the roll bar is down. Figure 8 1. Safe Zone-use the Z Master here on slopes less than 15 degrees or flat areas. 2.
Setting the Parking Brake 4. Move the PTO (power take off) switch to the off position (Figure 11). 1. Move the motion control levers (Figure 15) out to the neutral lock position. 2. Pull up and back on the parking brake lever to set the parking brake (Figure 10). The parking brake lever should stay firmly in the engaged position. 5. Move the throttle lever to the middle position (Figure 13). 6. Turn the ignition key clockwise to the run position (Figure 12). 7. Push the glow plug switch for 10 seconds.
Important: Use starting cycles of no more than 30 seconds per minute to avoid overheating the starter motor. Note: Do not use fuel left over from the summer. Use only fresh winter grade diesel fuel. Stopping the Engine 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake (Figure 14 ). Figure 12 1. Ignition switch 2. Off 2. Move the throttle lever midway between the slow and fast positions (Figure 13 ). 3. Run 4. Start 3.
2. While seated in the seat, release the pressure on the traction control levers and place in neutral. • The power take off (PTO) is disengaged. • The motion control levers are in the neutral locked position 3. Place the throttle in the fast position. Note: Engaging the PTO with the throttle at the half or less position will cause excessive wear to the drive belts.
Machine can spin very rapidly. Operator may lose control of machine and cause personal injury or damage to machine. • Use caution when making turns. • Slow the machine down before making sharp turns. Driving Forward 1. Release the parking brake; refer to Releasing the Parking Brake in Operation , page 14. 2. Move the levers to the center, un-locked position. 3. To go forward, slowly push the motion control levers forward (Figure 15).
2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Children or bystanders may be injured if they move or attempt to operate the tractor while it is unattended. 3. After adjusting the height-of-cut, adjust the rollers by removing the flange nut, bushing, spacer, and bolt (Figure 17 , Figure 18 and Figure 19 ). Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes.
Figure 20 3. Rotate cam to increase or decrease locking pressure 4. Slot 1. Cam lock 2. Lever Figure 19 1. Anti-scalp roller 2. Spacer 3. Bushing 4. Flange Nut 5. Bolt Positioning the Flow Baffle The following figures are only recommendations for use. Adjustments will vary by grass type, moisture content, and height of grass. Adjusting the Flow Baffle The mower discharge flow can be adjusted for different types of mowing conditions. Position the cam locks and baffle to give the best quality of cut.
Important: To adjust, move the lever sideways to unlock seat (Figure 24). Slide the seat to the desired position and release lever to lock in position. Figure 22 Position C Figure 24 This is the full open position. The suggested use for this position is as follows. • Use in tall, dense grass mowing conditions. • Use in wet conditions. • Lowers the engine power consumption. • Allows increased ground speed in heavy conditions. • This position is similar to the benefits of the Toro SFS mower. 1.
Pushing the Machine 1. Disengage the power take off (PTO) and turn the ignition key to off. Move the levers to neutral locked position and apply parking brake. Remove the key. Without the grass deflector, discharge cover, or complete grass catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris. Contact with rotating mower blade(s) and thrown debris will cause injury or death. 2. Rotate the by-pass valves counterclockwise 1 turn to push.
Loading Machines Use extreme caution when loading units on trailers or trucks. One full width ramp that is wide enough to extend beyond the rear tires is recommended instead of individual ramps for each side of the unit (Figure 27). The lower rear section of the tractor frame extends back between the rear wheels and serves as a stop for tipping backward. Having a full width ramp provides a surface for the frame members to contact if the unit starts to tip backward.
Mowing Direction shredding the grass blades. Tearing and shredding turns grass brown at the edges, which slows growth and increases the chance of disease. Check the cutter blades daily for sharpness, and for any wear or damage. File down any nicks and sharpen the blades as necessary. If a blade is damaged or worn, replace it immediately with a genuine TORO replacement blade. Alternate mowing direction to keep the grass standing straight.
Maintenance Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 8 hours • Check cooling system level. • Check the hydraulic fluid. After the first 25 hours • Change the hydraulic filter and oil. After the first 50 hours • Change the engine oil. • Change the engine oil filter. After the first 100 hours • Change gear box oil. Before each use or daily • • • • • • Check the safety system. Check the engine oil. Check cooling system level.
If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the ignition before you do any maintenance. Lubrication Where to Add Grease Greasing and Lubrication Lubricate the grease fittings as shown on the Check Service Reference Aid decal (Figure 28). Lubricate the machine when shown on the Check Service Reference Aid decal (Figure 28).
Greasing the Mower Deck and Belt Idlers 7. Grease the PTO drive belt idler arm (Figure 30). 8. Grease the pump belt idler arm (Figure 30). Service Interval: Every 25 hours Every 25 hours Every 25 hours Every 25 hours The mower deck must be lubricated weekly or every 25 hours. Grease with No. 2 general purpose lithium base or molybdenum base grease. Important: Make sure cutting unit spindles are full of grease weekly. 1.
Engine Maintenance Servicing the Air Cleaner Air Filter: Check and/or replace after every 250 operating hours or more often in dusty conditions. Note: Check the filters more frequently if operating conditions are extremely dusty or sandy. Removing the Air Filter Service Interval: Every 250 hours 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 2.
Figure 33 Checking the Engine Oil Level Service Interval: Before each use or daily Note: Check the oil when the engine is cold. 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. Figure 32 1. Air filter body 2. Air filter 3. Air cleaner cover 4. Latches 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Servicing the Engine Oil 3.
Figure 35 2. Drain plug 1. Back of machine Figure 34 1. Oil dipstick 2. Metal end Adding Engine Oil 3. Rear left side of machine 1. Tilt the seat forward and remove the front engine panel (Figure 36). Changing the Engine Oil Service Interval: After the first 50 hours Every 100 hours 1. Start the engine and let it run for five minutes. This warms the oil so it drains better. 2. Park the machine on a level surface. 3.
Figure 39 1. Note the clearance left in the filler opening. 5. Replace the dipstick and install the front engine panel. Figure 37 1. Engine 6. Start the engine and run it at idle for 5 minutes. 2. Oil fill cap 7. Shut off the engine. 8. Wait 3 minutes and check the oil level. 3. To add oil to the engine, locate and use a hose and funnel for adding oil (Figure 38). 9. Add oil, if required, to bring the level to the upper hole on the dipstick. 4.
Fuel System Maintenance Servicing the Fuel Filters Replace the fuel filters after every 400 operating hours or yearly, whichever occurs first, and replace them more frequently under extremely dusty or dirty conditions. Replacing the Fuel Filter Service Interval: Every 400 hours Ensure that an Authorized Service Dealer replaces the fuel filter and any components for the fuel system. Use of improper components can result in system failure, fuel leakage and possible explosion. Figure 40 1. Oil filter 2.
Electrical System Maintenance Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. Servicing the Battery • Always Disconnect the negative (black) battery cable before disconnecting the positive (red) cable.
Important: Always keep the battery fully charged (1.265 specific gravity). This is especially important to prevent battery damage when the temperature is below 32°F (0°C). 1. Make sure the filler caps are installed in battery. Charge battery for 10 to 15 minutes at 25 to 30 amps or 30 minutes at 10 amps. 2. When the battery is fully charged, unplug the charger from the electrical outlet, then disconnect the charger leads from the battery posts (Figure 44). 3.
Drive System Maintenance Adjusting the Tracking The machine has a knob for adjusting the tracking located under the seat. Important: Adjust the handle neutral and hydraulic pump neutral before adjusting the tracking. Refer to Adjusting the Handle Neutral in Controls System Maintenance , page 46 and Adjusting the Hydraulic Pump Neutral in Hydraulic System Maintenance , page 47. 1. Push both control levers forward the same distance. 2. Check if the machine pulls to one side.
Figure 47 Checking the Wheel Hub Slotted Nut Service Interval: Every 500 hours Check after every 500 operating hours. The slotted nut needs to be torqued to 125 ft-lb (170 N•m). 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the cotter pin. 4. Torque the slotted nut to 125 ft-lb (170 N•m) (Figure 48). Figure 46 1.
7. Torque the slotted nut to 125 ft-lb. (170 N•m) (Figure 48). Servicing the Gear Box 8. Tighten the nut until the next set of slots line up with the hole in the shaft (Figure 48). Checking the Gear Box Oil Level Service Interval: Every 100 hours 9. Replace the cotter pin. Yearly Use SAE 75W–90 Synthetic Gear Lube. Adjusting the Caster Pivot Bearing 1. Park the machine on a level surface. 2. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake.
Cooling System Maintenance Note: Do not open the radiator cap. Doing this may induce air into the cooling system. Servicing the Cooling System 1. Position the machine on a level surface, stop the engine, and set the parking brake. Cooling System Capacity: 176 ounces (4.6 l) 2. Unlatch the seat and tilt the seat up. 3. With the engine cool, check the overflow bottle level. The fluid needs to be up to the bump on the outside of the overflow bottle (Figure 51).
Brake Maintenance Adjusting the Parking Brake Service Interval: Every 25 hours Every 200 hours 1. Engage the parking brake, lever up. 2. Measure the length of the spring. Measurement should be 2-1/2 inch (64 mm) between the washers (Figure 53). 3. If adjustment is necessary, release the parking brake, loosen the jam nut below the spring and adjust the nut directly below the spring (Figure 53). Turn the nut until the correct measurement is obtained.
Belt Maintenance Inspecting the Belts Service Interval: Every 100 hours Inspect all belts every 100 hours. Check belts for cracks, frayed edges, burn marks or any other damage. Replace damaged belts. Replacing the Mower Belt Squealing when the belt is rotating, blades slipping when cutting grass, frayed belt edges, burn marks and cracks are signs of a worn mower belt. Replace the mower belt if any of these conditions are evident. 1.
Replacing the Pump Drive Belt Service Interval: Every 50 hours Check pump drive belt for wear after every 50 hours of operation. Note: Remove the PTO drive belt first if the pump drive belt needs to be replaced. 1. Tilt the seat forward and remove the front engine panel. 2. Remove the PTO drive belt. 3. Remove the spring from the idler arm (Figure 58). 4. Install the new belt around the engine and hydro pump pulley (Figure 58). 5. Install the PTO drive belt. 6.
3. Remove the 4 bolts holding the oil cooler shield to the rear frame (Figure 59). 9. Install a new belt around the pulleys and the alternator (Figure 61). 4. Remove the 3 bolts holding the engine straps to the side of the machine (Figure 59). 10. Install the fan and fan plate to the machine with the 2 bolts previously removed (Figure 60). 11. Install the oil cooler with the 4 bolts previously removed (Figure 60). 12.
Controls System Maintenance Adjusting the Control Handle Neutral Position If motion control levers do not align, or move easily into the console notch, adjustment is required. Adjust each lever, spring and rod separately. Note: Motion control levers must be installed correctly. See Installing the Motion Control Levers in the set up instructions. 1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 2.
Hydraulic System Maintenance 9. Apply slight rearward pressure on the motion control lever, turn the head of the adjustment bolt in the appropriate direction until the control lever is centered in the neutral lock position (Figure 63). Note: Keeping rearward pressure on the lever will keep the pin at the end of the slot and allow the adjustment bolt to move the lever to the appropriate position. Servicing the Hydraulic System 10. Tighten the nut and jam nut (Figure 63). Checking the Hydraulic Fluid 11.
1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Important: Do not substitute automotive oil filter or severe hydraulic system damage may result. Figure 64 1. Cap 2. Baffle 3. Place drain pan under filter, remove the old filter and wipe the filter adapter gasket surface clean (Figure 65). 3. Cold fluid level-full 4.
Checking the Hydraulic Hoses 9. Fill the hydraulic tank with hydraulic fluid until the fluid overflows the filter and then turn the oil filter clockwise until the rubber gasket contacts the filter adapter, then tighten the filter an additional 1/2 turn (Figure 67). Service Interval: Every 100 hours After every 100 operating hours, check the hydraulic hoses for leaks, loose fittings, kinked lines, loose mounting supports, wear, weather and chemical deterioration. Make necessary repairs before operating.
Engine must be running so motion control adjustment can be performed. Contact with moving parts or hot surfaces may cause personal injury. Keep hands, feet, face, clothing and other body parts away from rotating parts, muffler and other hot surfaces. 1. Raise the frame and block up the machine so drive wheels can rotate freely. 2. Disconnect the electrical connector from the seat safety switch. Temporarily install a jumper wire across terminals in the wiring harness connector. 3.
Mower Deck Maintenance Leveling the Mower at Three Positions Important: There are only three measuring positions needed to level the mower. Setting Up the Machine 1. Position mower on a flat surface. 2. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake. 3. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 4. Check tire pressure of all four tires.
Adjusting the Front-to-Rear Mower Pitch 1. Position the right blade front-to-rear (Figure 72). 2. Measure the right blade at the A location, from a level surface to the cutting edge of the blade tip (Figure 72). Figure 70 1. Measure here from blade to hard surface 2. Measure at B and C 7. If the measurements at positions B or C are not correct, loosen the bolt attaching the rear chain to the rear support arm (Figure 71). 8.
2. Check the distance between the two large washers, it needs to be 11-1/8 inches (28.2 cm) for 52 inch mower decks and 10-1/2 inches (26.7 cm) for 60 inch mower decks (Figure 73). A worn or damaged blade can break, and a piece of the blade could be thrown into the operator’s or bystander’s area, resulting in serious personal injury or death. 3. Adjust this distance, by loosening the spring jam nut and turning the nut in front of each spring (Figure 73).
Figure 75 1. Measure here from blade to hard surface 2. Position A 4. Rotate the opposite ends of the blades forward. 5. Measure from a level surface to the cutting edge of the blades at the same position as in step 3 above. The difference between the dimensions obtained in steps 3 and 4 must not exceed 1/8 inch (3 mm). If this dimension exceeds 1/8 inch (3 mm), the blade is bent and must be replaced; refer to Removing the Blades and Installing the Blades. Figure 74 1. Cutting Edge 2. Curved Area 3.
Installing the Blades 1. Install the blade onto the spindle shaft (Figure 78). Contact with a sharp blade can cause serious injury. Important: The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting. Wear gloves or wrap sharp edges of the blade with a rag. 2. Install the spring disk and blade bolt. The spring disk cone must be installed toward the bolt head (Figure 78). Torque the blade bolt to 85-110 ft-lb (115-150 N•m). 1.
Cleaning Note: Make sure the L end of the spring is installed behind the deck edge before installing the bolt as shown in Figure 79. Cleaning Under the Mower 3. Install the bolt and nut. Place the J hook end of the spring around the grass deflector (Figure 79). Service Interval: Before each use or daily Important: The grass deflector must be able to lower down into position. Lift the deflector up to test that it lowers into the full down position. Remove the grass buildup under the mower daily. 1.
Storage Note: A fuel stabilizer/conditioner is most effective when mixed with fresh fuel and used at all times. Cleaning and Storage B. Run the engine to distribute conditioned fuel through the fuel system (5 minutes). 1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to Off. Remove the key. C. Stop the engine, allow it to cool, and drain the fuel tank; refer to Servicing the Fuel Tank in Fuel System Maintenance , page 35. 2.
Troubleshooting Problem Starter does not crank Engine will not start, starts hard, or fails to keep running. Possible Cause 1. Blade control (PTO) is engaged. 1. Move blade contro (PTO) to disengaged. 2. 3. 4. 5. Parking brake is not on. Operator is not seated. Battery is dead. Electrical connections are corroded or loose. 6. Fuse is blown. 7. Relay or switch is defective. 2. 3. 4. 5. 1. Fuel tank is empty. 1. Fill fuel tank with fuel. 2. Air cleaner is dirty. 2.
Problem Uneven cutting height. Blades do not rotate. Possible Cause Corrective Action 1. Blade(s) not sharp. 1. Sharpen the blade(s). 2. Cutting blade(s) is/are bent. 3. Mower is not level. 4. Underside of mower is dirty. 5. Tire pressure is not correct. 6. Blade spindle bent. 2. Install new cutting blade(s). 3. Level mower from side-to-side and front-to-rear. 4. Clean the underside of the mower. 5. Adjust the tire pressure. 6. Contact an Authorized Service Dealer. 1.
Schematics Wire Diagram (Rev.
Notes: 61
Notes: 62
Evaporative Emission Control Warranty Statement California Evaporative Emission Control Warranty Statement Your Warranty Rights and Obligations Introduction The California Air Resources Board and The Toro® Company are pleased to explain the evaporative emission control system’s warranty on your 2006 model year equipment. In California, new equipment that use small off-road engines must be designed, built, and equipped to meet the State’s stringent anti-smog standards.
The Toro Total Coverage Guarantee Landscape Contractor Equipment (LCE) A Limited Warranty Conditions and Products Covered Owner Responsibilities The Toro® Company and its afliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair the listed Toro Products if defective in materials or workmanship.
